Terminal Removal
Follow the steps below in order to repair pull-to-seat connectors.
- Remove the terminal position assurance (TPA) device, the connector
position assurance (CPA) device, and/or the secondary lock.
- Separate the connector halves.
- Using the proper pick or removal tool insert into the front of
the connector body.
- Grasp the wire at the back of the connector body and gently pull
the terminal (1) from the connector body (3).
- Inspect the terminal for damage, if damaged refer to Terminal
Repair.
- Reform the locking tang (2) if the terminal is being reused.
Terminal Repair
- Slip the cable seal away from the terminal.
- Cut the wire as close to the terminal as possible.
- Slip a new cable seal onto the wire.
- Strip 5 mm (3/16 in) of insulation from the wire.
- Crimp a new terminal to the wire.
- Solder the crimp with rosin core solder.
- Slide the cable seal toward the terminal.
- Crimp the cable seal and the insulation.
- If the connector is outside of the passenger compartment, apply
grease to the connector.
Terminal Installation
- Inspect the terminal for damage. If damaged refer to Terminal
Repair.
- Reform the locking tang (2) if the terminal is being reused.
- Ensure that the cable seal is kept on the terminal side of the
splice.
- Insert the wire into the back of the connector body. Push until
the terminal locking tang locks into the connector body.
- Install the TPA, CPA and/or the secondary locks.